Industrial Insulation Manual

Industrial Insulation Process Manual

Industrial Insulation Process Manual Industrial & Mechanical Installation Guidelines

ROXUL INC.420 Bronte Street South,Suite 105,Milton, ON L9T 0H9T: 1 800 265 6878www.roxul.com

/TM: US - owner Rockwool International A/S used under license; Canada - owner Roxul Inc.

DISCLAIMER AND LIMITATION OF LIABILITY: The statements and data contained in this brochure are for general information purposes ONLY. They are NOT specific technicalrecommendations as to any particular design or application and the ultimate determination as to product suitability is the sole responsibility of the installer or end user. Although theinformation contained herein, including ROXUL product descriptions, is believed to be correct at the time of publication, accuracy cannot be guaranteed. ROXUL fully reserves the rightto make product specification changes, without notice or obligation, and to modify or discontinue any of its products at any time. In no event shall ROXUL be liable for any direct,indirect, or consequential damages of any kind arising from information contained in this brochure, including, but not limited to, claims for loss of profits, business interruption, ordamages to business reputation. This limitation of liability shall apply to all claims whether those claims are based in contract, tort, or any legal cause of action.

Surface Burning Characteristics: ULC Listed to Canadian Standard CAN/ULC S102 ; UL Classified to UL 723

A Global Leader

ROXUL Inc. is part of ROCKWOOL International, the largestproducer of stone wool insulation, which is made from naturalbasalt rock and recycled material. ROCKWOOL International wasfounded in 1909 and today operates worldwide with more than9,800 employees, with over 28 factories across three continents.

ROCKWOOL has over 75 years in the insulation business and for 25 years ROXUL has been serving the North American market,manufacturing stone wool insulation products for residential,commercial, industrial and OEM applications.

ROXUL is the Better Insulation

ROXUL is an innovative insulation offering a world of greenfeatures. When ROXUL is the specified insulation, companies willreceive a superior product along with the technical expertise of theROXUL team to meet all insulation requirements.

Environmentally Sustainable

Our stone wool production process utilizes some of the mostadvanced technology available. The last decade has seen a newgeneration of ROXUL manufacturing facilities that are designed tolower our environmental footprint. These endeavors haveincluded the capture and recycle rainwater, reduction in energyconsumption, and zero waste to landfill by the recycling of rawmaterials back into the production process. ROXUL facilities alsouse natural lighting and re-purpose water used during themanufacturing process to minimize the impact on the environmentand surrounding community resources.

ROXUL insulation is created using naturally occurring, inorganicraw materials and reuses waste from other manufacturers as wellas from our plants. Stone wool insulation is noncombustible andachieves its thermal performance without the use of blowingagents. The products therefore do not off-gas over time,contributing to a sustainable environment.

Each ROXUL plant uses a varying combination of new and recycledcontent in order to remain efficient and environmentally friendly.ROXUL is committed to improving our overall efficiencies whichfurther solidifies our commitment to environmental stewardshipwithin the organization.

For further details contact your ROXUL sales representative.Please visit www.roxul.com for the latest information.

Contents

1. System solutions 7

1.1 Planning and preparation 111.2 Insulation of piping 231.3 Insulation of vessels 471.4 Insulation of columns 531.5 Insulation of storage tanks 591.6 Insulation of boilers 671.7 Insulation of flue gas ducts 751.8 Cold boxes 82

2. Theory 85

2.1 Norms & Standards 882.2 Product properties & test methods 1072.3 Bases for thermal calculations 120

3. Tables 127

3.1 Units, conversion factors and tables 1303.2 Product properties insulation and cladding materials 1463.3 Usage tables 149

4. Products 169

ProRox PS 960NA 171ProRox PS 980NAENERWRAP MA 960NAProRox SL 920NAProRox SL 930NAProRox SL 940NAProRox SL 960NAProRox SL 540NAProRox SL 560NAProRox SL 590NAProRox SL 430NAProRox SL 450NAProRox SL 460NAProRox SL 760NAProRox FSL 920NAProRox FSL 930NAProRox FSL 940NAProRox FSL 960NAProRox MA 930NAProRox MA 940NAProRox GR 903ProRox LF 970ProRox Rocktight

Overview: ROXUL Industrial Insulation Solutions

1.2.1 Insulation with pipe sections 29 1.6.1 Insulation of fire tube boilers 67

1.6.2 Supercritical steam generators 69

1.2.7 Insulation of valves and flanges 40

1.2.8 Insulation of pipe elbows and T pieces 42

1.2.9 Reducers 43

1.2.10 Expansion joints 44

1.2.11 Tracing 45

1.2.12 Foot traffic 46

1.2 Insulation of piping 23 1.6 Insulation of boilers 67

1.4 Insulation of columns 53

1.5 Insulation of storage tanks 59

1.7 Insulation of flue gas ducts 75

1.8 Cold boxes 82

1.3 Insulation of vessels 47

1.2.2 Insulation with pipe wraps (mats) 31

1.2.3 Insulation with wired mats 33

1.2.4 Insulation support 34

1.2.5 Cladding 36

1.2.6 Pipe hangers and pipe support 39

Contents1. System solutions 7

1.1 Planning and preparation 111.2 Insulation of piping 231.3 Insulation of vessels 471.4 Insulation of columns 531.5 Insulation of storage tanks 591.6 Insulation of boilers 671.7 Insulation of flue gas ducts 751.8 Cold boxes 82

2. Theory 85

2.1 Norms & Standards 882.2 Product properties & test methods 1072.3 Bases for thermal calculations 120

3. Tables 127

3.1 Units, conversion factors and tables 1303.2 Product properties insulation and cladding materials 1463.3 Usage tables 149

4. Products 169

ProRox PS 960NA 173ProRox PS 980NA 173ENERWRAP MA 960NA 174ProRox SL 920NA 175ProRox SL 930NA 175ProRox SL 940NA 176ProRox SL 960NA 176ProRox SL 540NA 177ProRox SL 560NA 177ProRox SL 590NA 178ProRox SL 430NA 179ProRoxv SL 450NA 179ProRox SL 460NA 180ProRox SL 760NA 180ProRox FSL 920NA 181ProRox FSL 930NA 181ProRox FSL 940NA 182ProRox FSL 960NA 182ProRox MA 930NA 183ProRox MA 940NA 183ProRox GR 903 184ProRox LF 970 184ProRox Rocktight 185

ROXUL insulation provide superior thermal and acoustical performance and are fire resistant, water repellent, non-corrosive and resistant to mold. Specialists often willingly turn to our products and expertise in industrial and marine & offshore insulation. We have now packaged that expertise into a practical guide: the 'ProRox insulation Process Manual.

This manual offers a transparent overview of our ProRox product range, including thermal, fire-resistant, compression, comfort/multi-purpose, fabrication and acoustic insulation solutions for technical installations in the process & power generation industries.

The Process Manual is a convenient resource tool with relevant information at your finger-tips. Fold-out sections take you directly to the right page, whether you are looking for straight forward piping insulation or more complex applications for columns, tanks and boilers. In addition to pictures and photographs, a range of tables and diagrams are included.

The ROXUL Process Manual is a helpful tool for the application of our ProRox industrial insulation solutions in a process environment. Should you need any further information about a specific application, procedure or practical problem, please consult www.roxul.com or contact your local ROXUL representative at 1 800 265 6878.

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ROXULIndustrial InsulationROXUL - an independent organization with the ROCKWOOL Group - is a leading supplier of high quality stone wool products in the industrial insulation market. With the ProRox & SeaRox lines for the industrial market and for the marine & offshore industry, our experts provide a full range of products and systems for the thermal, acoustic and firesafe insulation of industrial installations. ROXUL continuously monitors the market developments. Our 75+ years of global experience is reflected in a complete set of high-grade products and expert advice. Today, we remain fully committed to providing the very best service in the market and a total range of cutting-edge insulation solutions.

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The ROXUL IndustrialInsulation Process ManualKnow-how for designers, engineers, site supervisors and managers of industrial plants

Energy keeps the world in motion. Without it, everything would come to a standstill. The global economy is dependent upon a secure & efficient supply of energy. Over eighty percent of the energy currently being consumed is obtained from non-renewable resources. Those resources are becoming increasingly scarce, while at the same time the demand for energy is exploding. This means that owners, designers and operators of large, industrial plants are challenged with the task of reducing their energy consumption as much as possible in order to ensure the long term sustainability of their operations.

Solar energy is just one of the possible alternatives. Through, for example, solar power plants we already succeed in converting concentrated sunlight very efficiently into electricity. And this is just one of the solutions that can help us drive down fuel consumption and carbon emissions.

On top of that, insulation significantly reduces the energy needed to manufacture a product or provide a service. Also, new technologies for emission controls at existing fossil burning facilities is greatly enhanced by insulation. Nowadays there are a variety of efficient insulation systems that enable scarce

energy reserves to be put to the best possible use. The ROXUL Industrial Insulation Process Manual illustrates these systems both theoretically and practically. This process manual targets designers, engineers, installers and managers of industrial plants and provides an overview of the modern insulation techniques for, by way of example, chemical or petrochemical installations and power generation facilities. Based on current standards and regulations the manual provides accessible, practical guidelines for the implementation of numerous insulation applications.

Restriction of thermal losses to an absolute minimum, including during transfer or storage, can considerably reduce the energy consumption of industrial plants. This also results in a reduction in carbon dioxide (CO) emissions, which are created each time fossil fuels such as coal or gas are burnt and which, as a greenhouse gas, is responsible for the global increase in temperature.

From an environmental perspective, adequate insulation of industrial plants is a significant means of reducing (CO) emissions.

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Flow Of Energy

In addition, the right insulation keeps temperatures, for example in pipes and storage tanks, within strict tolerances, thereby ensuring reliable process efficiency. At the same time, adequate insulation protects the plant itself. Modern insulating materials can thoroughly protect plant components from moisture and associated corrosion. Installation and process maintenance costs can be reduced considerably and the effective lifetime ofindustrial plants can be successfully maximized.

Furthermore, industrial insulation also provides a significant contribution to personnel protection. Optimum insulation reduces process temperatures and noise in the industrial environment to an acceptable level, to the limits generally regarded in the industry to be those required for a safe and comfortable working environment.

With a complete range of techniques and insulation systems, ROXUL offers designers, engineers and construction supervisors optimum tailored solutions for the petrochemical, power generation, ship building, offshore and processing industries.

In the 'Flow of Energy' diagram on the following page, you will find an overview of all of the sectors in which ROXUL is active. All of our ProRox (and SeaRox) products, such as pipe sections and boards (slabs) are designed to meet the highest quality and safety standards and comply with the strictest, and therefore safest, fire safety classes. Stone wool is non flammable, non combustible and can withstand temperatures up to 2150 F (1177 C) and therefore provides a crucial contribution towards passive fire protection.

As a supplement to this process manual, ROXUL also regularly provides infor mation about technical innovations, product solutions and recent and relevant documents available online at our website www.roxul.com. NOTE: The process manual is a guideline and can only provide general advice for specific instances in the field of plant and processes. For these instances, the ROXUL Technical Services Team is available to provide advice during the design, engineering and implementation phases. Please find our contact details on the back cover of this manual.

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Petrochemicals

Oil

Gas

Coal

Waste

Gas Processing

End Products

Exploration, drilling and production

Processing industry

Consumption

Flow of energy

Industrial

Marine

Oshore

Power Plant

Solar Power Plant

Petroleum Rening Processing

Non-residential

Residential

Sun

Business Areas:ProRox insulation for industry:Our ProRox product line covers all our thermal, fire-resistant, compression, comfort/multi-purpose, fabrication and acoustic insulation solutions for industrial installations in the process industry.

SeaRox insulation for shipbuilding and offshore:SeaRox comprises the full marine and offshore product line. This sharp focus enables us to combine our expertise and extensive experience like never before to develop outstanding insulation solutions for our customers.

ProRox

SeaRox

ROXUL Industrial Insulation, Flow of Energy

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1Industrial insulation System solutions

Table of contents

1.1 Planning and preparation 111.1.1 Decision criteria for the design of an insulation system 11 A. Functional requirements 12 B. Safety aspects 16 C. Economics 17 D. Environmental 18 E. Corrosion Prevention 18 1.1.2 Design & planning of the insulation work 191.1.3 Corrosion prevention 191.1.4 Storage of insulation materials 22

1.2 Insulation of piping 231.2.1 Insulation with pipe sections 291.2.2 Insulation with pipe wraps (mats) 311.2.3 Insulation with wired mats 331.2.4 Insulation support 341.2.5 Cladding 361.2.6 Pipe hangers and pipe supports 391.2.7 Insulation of valves and flanges 401.2.8 Insulation of pipe elbows and Tpieces 421.2.9 Reducers 431.2.10 Expansion joints 441.2.11 Tracing 451.2.12 Foot traffic 46

1.3 Insulation of vessels 47

1.4 Insulation of columns 53

1.5 Insulation of storage tanks 59

1.6 Insulation of boilers 671.6.1 Insulation of fire tube boilers 67 1.6.2 Supercritical steam generators 69

1.7 Insulation of flue gas ducts 751.7.1 Installation of the insulation systems for flue gas ducts 751.7.2 Cladding of flue gas ducts 781.7.3 Acoustic insulation of flue gas ducts 81

1.8 Cold boxes 82

1. System solutions

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Notes

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1.1 Planning and preparationThe design of a suitable insulation system for industrial installations is a major factor for its economical operation, functionality, security, durability and environmental impact. Additionally, the installation-specific heat losses are specified for the entire life cycleof the plant. Corrections at a later stage, such as subsequently increasing the thickness of the insulation, for example, may no longer be possible due to lack of space. Correc-tions at a later stage may also entail a far greater investment compared to the original planning. Continually rising energy costs are also often overlooked factors when dimensioning the insulation. Insulation thicknesses that are designed to last take energy price increases into account. They form an important criterion for the economical operation of the installation after just a few years.

Properly dimensioned insulation systems constitute an important contribution to environmental protection, carbon dioxide (CO) reduction and to economic success. CO reduction is also an economical operation, as it lowers the costs for CO emission certificates. Nowadays, conservational and economical operations are no longer conflicting ideas, but are two inseparable parameters.

1.1.1. Decision criteria for the design of an insulation system

Selecting a suitable insulation system depends on the following five parameters:

1. Functional requirements a. Object dimensions b. Operation of the installation c. Operating temperatures d. Permissible heat losses or temperature

changes ofthe medium e. Frost protection f. Ambient conditions g. Maintenance and inspection

2. Safety aspects a. Personal protection b. Fire protection c. Explosion prevention d. Noise reduction within the plant

3. Economics a. Economical insulation thickness

b. Pay-back time 4. Environment 5. Corrosion prevention

1. System solutions

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1.1 Planning and preparation

40 (1000) 40 (1000)

40 (1000)

31.5 (800)

A. Functional requirementsa) Object dimensionsThe space requirements of the insulation must be taken into account when the installation is being designed and planned. Therefore, the insulation thicknesses should be determined in the early planning stages and the distances between the individual objects should be taken into account in the piping isometrics. To guarantee systematic installation of the insulation materials and the cladding without increased expense, observe the minimum distances between the objects asspecified in the following illustrations.

Minimum distances between vessels and columns; dimensions in inches (mm)

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Minimum distances within range of pipe flanges; dimensions in inches (mm)

4 (100) 4 (100) 4 (100) 4 (100) 4(100)

a = distance flange to normal insulationa 2" (50 mm)x = bolt length + 1.2" (30 mm)s = insulation thickness

4 (100)

4 (100)

Minimum distances between insulated pipes; dimensions in inches (mm)

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1.1 Planning and preparation A. Functional requirementsb) Operation of the installationTo select a suitable insulation system, the operating method of the installation must be considered. A basic distinction is made between continuous and interrupted operation. With continuous operation, the operating temperatures are constantly above or constantly below the ambient temperatures. The interrupted operating method, also referred to as intermittent or batch operation, is characterized by the fact that the installation is switched off between each operating phase and during that time can assume ambient temperatures. For special applications, e.g. dualtemperature systems, the operating temperature alternates above or below the ambient temperature.

c) Operating temperatureThe appropriate insulation material should be resistant to the intended operating/peak temperatures. Thisproduct property is assessed by the maximum service temperature (also see Chapter 2.2 Product properties & test methods).

d) Permissible heat losses or temperature changes ofthemedium

With many technical processes, it is essential that media in vessels, columns or tanks do not fall below a specific lower temperature limit, otherwise chemical processes will not proceed as intended or the media will set and can no longer be pumped or extracted. Over-cooling can lead to the precipitation of, for example, sulphuric acid in exhaust and flue gas streams, which promotes corrosion in the pipes or channels. With flowing media, it is essential to ensure that the temperature of the medium is still at the desired level at the end of the pipe. The thermal insulation is designed according to these requirements. Under extreme conditions (e.g. lengthy periods of storage, longtransport routes or extreme temperatures), installing tracing may be necessary, to ensure that the media is kept within the required temperature limits.

Thermo-technical engineering calculation programs like NAIMA's 3E Plus or ROXUL's "ROCKASSIST" (coming soon) can aid in ensuring the optimum engineering and design ofthese insulation systems. More information can be found on our website www.roxul.com. For special situations please contact the ROXUL Technical Services Team for further guidance.

Inside buildings, uninsulated or poorly insulated parts of installations unnecessarily increase room temperatures, which can have a negative effect on the working environment - both for the people who work long hours under these conditions and for the electronic components. In addition to the increased heat loss, the need for climate controlled rooms requires further energy consumption. The design of the insulation and the related reductions in terms of heat loss from parts of installations should be relevant to the entire infrastructure and use of the building.

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e) Frost protectionInstallations that are situated outside are at risk from frost in the winter. In addition to the malfunctioning of installations, installations also risk damage caused by the expansion of frozen water. Adequate measures against frost protection are critical to protect the installation from freezing. Insulation can reduce heat loss and aid in frost protection. Insulation alone cannot indefinitely prevent the installation from freezing. Installing additional tracing may be necessary between the object and the insulation. To prevent freezing, the insulation must be designed so the heat flow rate of the insulated object is less than the heat provided by the tracing.

f) Ambient conditions Select an insulation system that offers long-lasting resistance to the surrounding environme nt.

Atmospheric influences: wind, rain Mechanical loads such as vibrations or

foottraffic Corrosive environment (proximity to sea,

chemicals,)

Moisture accumulation in insulation increases thermal conductivity and the risk of corrosion of the insulated installation components. Cladding must be installed to prevent the ingress of moisture into the system. If the ingress of moisture into the insulation is unavoidable, retain

an air space of at least 2/3 (15 mm) between the insulation and the cladding, and create 0.4 (10 mm) diameter ventilation and drain holes in the covering at intervals at a maximum of 12" (300 mm). If necessary, the insulation and cladding must resist chemical influences that develop within the environment.Installations operating below ambient temperatures have a high risk of moisture condensing from the ambient air inside the cladding. Use a continuous vapor retarder on piping operating below ambient temperatures and seal all joints, surfaces, seams and fittings to prevent condensation (use of staples is not recommended).

g) Maintenance and inspection To avoid complicating routine maintenance and inspection work unnecessarily, maintenance-intensive areas must be taken into account, especially when designing the insulation work. Removable insulation systems, such as removable coverings and hoods, could be fitted in such areas, for example. Easily removable covering systems are also recommended for flanges and pipe fittings. These coverings are generally fastened with quick-release clamps, which can be opened without special tools.The insulation of fixtures such as flanges or pipe fittings must be interrupted at a sufficient distance to allow installation or dismounting to be carried out. In this case, take the bolt length at flange connections into consideration. Any fixtures in the range of the insulation, including the interruption in the installation, should be insulated with removable coverings overlapping the insulation and maintaining continuity across the fixture.

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1.1 Planning and preparation1.1 Planning and preparation

B. Safety aspectsa) Personal protectionSurface temperatures in excess of 140 F (60C) can lead to skin burns, if the surface is touched. Therefore, all accessible installation components should be designed to protect personnel and prevent injuries. The insulation applied to such plant components must ensure that surface temperatures in excess of 140 F (60C) do not occur during operation. Consult our Technical Services Team to determine the required insulation thickness to aid in personnel protection. All of the operational parameters must be known to achieve a reliable design, including, for example, the temperature of the object, the ambient temperature, air movement, surface materials, distance from other objects, etc.

NoteAs the surface temperature depends on a set of physical parameters, which cannot always be calculated or estimated with any degree of certainty, the surface temperature is not a guaranteed measurement. If the required protection (temperature) cannot be achieved by insulation, apply additional protective devices, such as safety guards or enclosement of theobject.

b) Fire protectionThe general fire protection requirements imposed on structural installations are usually defined within the local Building Codes or the specifications of plant owner. Structural installations must be designed, built, modified and maintained to prevent the outbreak of a fire and the spread of fire and smoke. In the event of a fire, the rescuing of people and animals and effectively extinguishing the fire must be made possible. During the design of the installation, it is vital to determine the nature and scope of the fire prevention measures together with the building supervisory board, the fire department, insurance

companies and the operator.As a basic principle, consider the fact that the fire load in a building or industrial installation can be considerably increased by flammable insulation materials. On the other hand, non-flammable insulation materials such as mineral wool (stone wool), which has a melting point of >2150 F (>1,177 C), not only have a positive impact on the fire load, but in the event of a fire, also constitute a certain fire protection for the installation component.

Installation components with tracing, in particular, which use thermal oil as a heat transfer medium, have an increased risk of catching fire in the event of a leak. In this case, ensure that the thermal oil cannot penetrate into the insulation material.

c) Explosion preventionIf there is a risk of fire and explosion, the surface temperature of the object and the cladding must be considerably lower than the ignition temperature of the flammable substance and/or gas mixtures. This requirement also applies to thermal bridges, such as pipe mounting supports, supporting structures and spacers etc.With regard to insulation systems, explosion

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protection can only be achieved with a doubleskin covering. A doubleskin covering is a factory made cladding that has been welded or soldered to make it air proof and diffusion-resistant. In addition special (local) explosion regulations must be observed.

In explosive areas electrostatically charged substances like unearthed cladding or non-conductive plastics must be grounded (earthed). For further guidance please consult your local safety guidelines relating to static electricity.

d) Noise protectionThe guidelines for noise in the ordinance and workplace are stated in the local regulations and standards. Generally, the level of the guideline values depends on the nature of the activity.

The sound propagation of installation components can be reduced using insulation systems. The nature and effect of the sound insulation depend onthe frequency and the sound pressure level.

C. economicsIn the industry there are two grades of insulation. The first grade focuses on reducing heat losses and the prevention of injuries to people operating or working nearby the installations. The second grade of insulation, the so called economical insulation thickness focuses on significant heat loss reduction and as a result achieving a better return on investment.

a) Economical insulation thicknessInsulation reduces the heat losses from the object. Thethicker the insulation, the greater theheat reduction and consequently, the more energy is saved. However, the investment and expenditure, e.g. for depreciation, interest rates and higher maintenance costs also rise ifthe insulation thickness is increased. At a certain insulation thickness, the sum of the two cost flows reaches a minimum. This value is known as the economical insulation thickness. Aqualitative curve of a similar costs function is shown below.

The energy costs cannot be based solely on the current price. Developments over recent years indicate energy costs will continue to rise.

Cos

ts

Insulation costs

Economical insulation thickness

Total costs

Heat loss costs

Insulation thickness

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1.1 Planning and preparation1.1 Planning and preparation C. economicsIncreasing energy prices are tending to bring about a shift in economic insulation thicknesses towards larger thicknesses.

b) Pay-back timeIn addition to the economical insulation thickness, another frequently used economical parameter is the return on investment period (ROI), also referred to as the payback period. This is defined as the period within which the cost of the insulation is recuperated through savings on heat loss costs.

ROI period =Costs of the insulation

[a]annual saving

In the case of industrial insulation systems, the return on investment period is generally very short, often being much less than one year. Considering only the return on investment period, however, can be deceptive, as this approach disregards the service life of the installation.With long-life installations, it is advisable to select higher insulation thicknesses, even if this means accepting a longer return on investment period. Throughout the entire service life of the installation however, the increased insulation thickness results in a significantly higher return on the investment in insulation and achieves a much more economic operation of the installation.

D. environmentalThe burning of fossil fuels, such as coal, oil or gas, not only depletes the available primary energy sources, but also, due to the emission of carbon dioxide (CO) into the atmosphere, places aburden on the environment.

The increasing CO concentration in the Earths atmosphere plays a significant part in the global increase in temperature, also referred to as the greenhouse effect. CO absorbs the thermal radiation emanating from the earths surface andin doing so reduces the dissipation of heat into space. This is leading to a change in the worlds climate with as yet inestimable consequences. Reducing CO emission can only beachieved through more efficient management of fossil fuels. Increasing the insulation thicknesses is essential for the reduction of CO emissions.

Reducing CO emissions also has a positive financial benefit for businesses within the context of an emissions trading scheme. The benefits of increased insulation thicknesses in industrial installations are twofold, as the costs for both energy consumption and CO emissions are decreased.

e. Corrosion PreventionSee Chapter 1.1.3

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1.1.2 Design & planning of the insulation work

Requirements for insulation work must be included in the design and construction phase of industrial plants. It is advisable to involve all project managers at an early stage to avoid unnecessary issues or delays.

All preparatory works must be completed according to the relevant insulation standards. The following preconditions must be fulfilled:

If necessary, work has been carried out on the object to protect against corrosion

Tracing and technical measurement equipment have been installed

The minimum distance between the objects hasbeen observed (see illustrations on pages 12and 13)

Surfaces have no coarse impurities Mounting supports have been installed on the

object to accommodate the support structure Collars and sealing discs have been fitted to

theobject Taps on the object are long enough to ensure

that flanges lie outside the insulation and can be screwed on without hindrance

Supports are designed so that insulation, watervapor retarders and cladding can be professionally installed

The insulation can be applied without any obstacles (e.g. scaffolding)

Welding and bonding work has been carried out on the object

The foundations have been completed

1.1.3 Corrosion preventionIndustrial facility disruptions are due to the lack of, or inadequate forms of, protection against corrosion. This considerably reduces the service life of industrial plants, and more frequently, essential shutdown or overhaul work impairs the efficiency of the installation.It is commonly, but wrongly, assumed that the insulation system also protects an installation against corrosion. For each installation it must be determined whether protection against corrosion is required and, if so, which are the appropriate measures.

Generally, the design of the insulation system & corrosion protection will depend on the following parameters.

Operation of the installation - Continuous operation - Interrupted/intermittent operation - Operation involving varying temperatures - Type of plant (e.g. Petrochemical, pharmaceutical, etc)

Operating and Ambient temperatures of the installation

Metals and Materials Used - Non-alloy or low-alloy steel - Austenitic stainless steel - Copper

External influences upon the installation - Environment of the installation (chemically

aggressive?) - Location

The best practices may vary per country and/or standard. The design of corrosion protection is often carried out on the basis of a small selection of standards, such as ASTM C795, that do not adequately take into account all the specific features of protecting against corrosion in insulation systems. For further details on corrosion protection we recommend referring NACE SP0198 and the RoXUL Corrosion Under Insulation (CUI) brochure.

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1.1 Planning and preparation1.1 Planning and preparation 1.1.3 Corrosion prevention

In the case of cold insulation, if the object is made of non-alloy or low alloy steel, it must be protected against corrosion.

In the case of objects made, for example, of austenitic stainless steel or copper, the installation must be tested in each individual case by the planner to determine whether protection against corrosion is necessary.

Objects made from austenitic stainless steel do not require protection against corrosion if the temperature never even for a short period exceeds 120 F (50 C)

Note Protection against corrosion should be applied in the case of all installations made from non-alloy or low-alloy steel where the operating temperatures are below 250 F (120 C). Protection against corrosion may be omitted in the case of:

Installations operating continuously under extremely cold conditions [below -50 F (-50 C)] such storage tanks.

Insulated surfaces of power plant components, such as boiler pressure components, flue gas and hot air ducts and steam pipe systems with operating temperatures that are constantly above

250 F (120 C).

If austenitic stainless steel is insulated with any type of insulation - For temperatures of up to 930 F (500 C), aluminum foil of not less than .06 mm thick to be applied to the steel surface, arranged to shed water with overlaps of not less than 2" (50 mm) at the joints.

CINI Manual Insulation for industriesCINI recommends applying corrosion protection prior to the insulation work at any time.

In all phases, pay attention to CUI (corrosion under insulation) prevention: design, construction, paint & coating work, application of the insulation system, inspection and maintenance. Equipment and piping sections like nozzles, supports etc. should be designed and maintained to prevent ingress of water into the insulation system.

The paint specifications are split up into: - Construction material

(carbon steel, stainless steel) - Temperature ranges from -22 F (-30 C) to

1000 F (540 C) with special attention to the temperature range between 0 F (-20 C) and 300 F (150 C).

The corrosion protection can be achieved using aluminum foil wrapping, thermal sprayed aluminum (TSA) or paint.

Protection against corrosion may be omitted in the case of installations operating continuously under extremely cold conditions [< -22 F (-30 C)]

Application Before applying corrosion protection coating, the surface must be free from grease, dust and acid and, for better adhesion, the priming coat should be roughened. Blasting is recommended as a surface preparation method (with austenitic stainless steel, use a ferrite free blasting abrasive).Observe the corresponding processing guidelines of the coating manufacturer. If metals with different electrochemical potentials, such as aluminum and copper, come into contact with one another, there is a risk of electrochemical corrosion. If necessary, this can be avoided using insulating, intermediate layers such as non- metallic straps. The presence of moisture will increase the development of electrochemical corrosion.

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The table further on this page, which has been derived from the standard DIN 4140, indicates the initial risks of electrochemical corrosion in cases where various combinations of metals are used.

Note The table does not take into account forms ofcorrosion with other root causes, such as stress corrosion. For further information, see Chapter 2.2 Product properties & test methods AS-Quality on page 115.

Material Combination material

Metal Surface ratio in proportionto combinationmaterial Zinc AluminumFerritic

steel LeadAustenitic stainless

steelCopper

ZincSmall - M M H H H

Large - L L L L L

AluminumSmall L - L H H H

Large L - L M L H

Ferritic steelSmall L L - H H L

Large L L - L L L

LeadSmall L L L - H H

Large L L L - M M

Austenitic stainless steel

Small L L L L - M

Large L L L L - L

CopperSmall L L L L L -

Large L L L L L -

L - Light or little corrosion to material M - Moderate corrosion to material, for example, in very humid atmospheresH - Heavy electrochemical corrosion to material

Observation: The table shows the corrosion of the material, and not that of the combination material.Light means: small-scale in proportion to the combination material, heavy means: large-scale in proportion to the combination material.

Example 1: Material is a zinc galvanized screw in combination material, a cladding made from austenitic stainless steel: Row zinc small: H heavy corrosion of the screw.

Example 2: Material , a cladding made from austenitic stainless steel screwed on with a screw galvanized with combination material zinc: Row austenitic stainless steel large. L the corrosive attack upon the austenitic steel is light.

Electrochemical Corrosion Potential

21


1.1.4 Storage of insulation materialsIncorrect storage of insulation materials outdoors can cause insulation to deteriorate. Insulation should be protected when stored, during installation and when fitted to minimize moisture exposure, physical damage and contamination. If storage indoors is not possible, protect the insulation material from weather influences by covering it with waterproof material. Insulation should also be stored a minimum of four inches above ground and kept on a solid surface away from ponding water and ground moisture.

Moisture causes many types of corrosion that virtually never develop in a dry system. The major types of corrosion in relation to insulation technology are oxygen, electrochemical and stress corrosion. Insulation materials that are manufactured with properties (such as low chloride content or added inhibitors) can irrevocably lose these properties when exposed to contamination or additives are leached out.

The thermal conductivity of water is approximately 25 times greater than that of air. An increase in moisture therefore results in an increase in the thermal conductivity of the insulation and, correspondingly, a decrease in the insulation efficiency. Higher moisture can also mean a significantly higher weight, which, as a rule, is not taken into account in the static design of an insulation system. It is therefore important to protect the insulation from moisture after installation, as well as ensure insulation is thoroughly dry when installed (especially in sealed application at low temperatures or where the temperature cycles).

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1. System solutions1.2 Insulation of piping Piping plays a central role in many industrial processes in chemical or petrochemical installations such as power plants, as it connects core components such as appliances, columns, vessels, boilers, turbines etc. withone another and facilitates the flow of materials andenergy. Toguarantee a correct process cycle, the condition of the media within the pipes must remain within the set limitations (e.g. temperature, viscosity, pressure, etc.). In addition to the correct isometric construction and fastening of the piping, the piping insulation also has an important function. It must ensure that heat loss are effectively reduced and that the installation continues to operate economically and functionally on a permanent basis. This is the only way to guarantee the maximum efficiency of the process cycle throughout the design service life without losses as a result of faults.

Requirements for industrial pipingThe basic efficiency and productivity factors of piping for the processing industry include: energy efficiency, dependability and reliability under different conditions, functionality of the process control, appropriate support structure suitable for the operating environment, as well as mechanical durability. The thermal insulation of piping plays a significant role in fulfilling these requirements.

thermal insulationThe functions of proper thermal insulation for piping include:

Reduction of heat losses (cost savings) Reduction of CO emissions Frost protection Process control: ensuring the stability of

theprocess temperature Noise reduction Condensation prevention Personnel protection against high temperatures

ProRox products for pipe insulationROXUL Inc offers a wide range of high-quality stone wool insulation products for the insulation of industrial plants. These products are part of our extensive ProRox range for industrial insulation. With this specific field of application in mind we developed our pre-formed pipe sections and pipe wrap (mat) products for pipe insulation. All these products are easy to install and contribute to a high level of efficiency, functionality and reduced heat losses. Continuous internal and external inspection and high levels of quality assurance ensure the consistently high quality ofall ROXUL products.

The examples of use below cannot fully take into account the particular circumstances of the construction-related factors. Determine whether the products are suitable for the corresponding application in each individual case. If in doubt, consult the ROXUL Technical Services Team.

The applicable standards and regulations must also be observed. A few examples follow:

NACE SP0198 (Control of corrosion under thermal insulation and fireproofing materials - a systems approach)

MICA (National Commercial & Industrial Insulation Standards)

DIN 4140 (Insulation works on technical industrial plants and in technical facility equipment) AGI Q101 (Insulation works on power plant components) CINI-Manual Insulation for industries BS 5970 (Code of practice for the thermal

insulation of pipework, ductwork, associated equipment and other industrial

installations) 23

1.2 Insulation of piping

Hot insulation systems Principally, a thermal insulation structure for piping consists of an appropriate insulating material, usually covered by sheet metal cladding. This protects the object and the insulation from external influences such as the weather and mechanical loads. Spacers are also essential with insulation such as wired mats, which do not offer sufficient resistance to pressure to hold the weight of thecladding and other external loads. These spacers transfer the cladding loads directly onto the object. In thecase of vertical piping, support structures are fitted totake on the loads of the insulation and the cladding. Ingeneral, support structures and spacers form thermal bridges.

Selecting a suitable insulation system depends on numerous parameters. These are described in greater detail in Chapter 1.1. Regarding the different forms of pipe insulation, a fundamental distinction can be drawn between the following insulation systems.

Insulation with pipe sections Generally, the best insulation is achieved using ProRox Pipe Sections and can be used up to temperatures of 1400 F (760 C) when using ProRox PS 980NA Type V insulation. They are supplied ready split and hinged for quick and easy snap-on assembly and are suitable for thermal and acoustical insulation of industrial pipe work.Due to their excellent fit and high compression resistance, pipe sections can often be applied in asingle layer without any additional spacers.If multiple layers are required, ROXUL can also supply double layered - nested - pipe sections.This reduces installation costs considerably. Also the number of thermal bridges, which have a negative influence on the insulation, is greatly reduced, while a lower thickness may be applied compared to wired mats.

Using pipe sections for the insulation of pipes results in considerably reduced installation time and costs. The lack of spacers and unforeseen

gaps minimizes heat losses and the risk of personal injuries due to hot spots on the cladding. At temperatures above 550 F (300 C), the provisional application of spacers must be determined in each individual case.

Pipe sections are always precisely tailored to the corresponding pipe diameter to minimize the risk of convection and processing defects. ROXUL pipe sections are available in diameters of NPS 1/2" (23 mm) to NPS 28" (713 mm).

Insulation with load-bearing pipe wraps (mats) Load-bearing pipe wraps (mats), such as ENERWRAP MA 960NA are the latest development in the insulation sector. ENERWRAP MA 960NA is a stone wool (mineral wool) insulation wrap available with a black mat or reinforced foil facing and is designed for easy installation of large diameter pipes. Typical applications include:

pipe diameters >NPS 12" (326 mm), or; piping with a high number of shaped pieces

such as elbows or T-joints.

ENERWRAP MA 960NA can be applied up to temperatures of 1200 F (650 C). It is highly compression resistant and can be applied without any additional spacers.

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Consequently the number of thermal bridges, which have a negative influence on the insulation, is greatly reduced.

The result is considerably reduced installation time and costs. The lack of spacers and unforeseen gaps minimizes heat losses and the risk of personal injuries due to hot spots on the cladding. Pipe wraps (mats) are tailored to the corresponding length of the pipe circumference on site and are fastened with clamps.

Insulation with wired mats Wired mats, are lightly bonded stone wool wraps (mats), usually stitched with galvanized wire onto a galvanized wire mesh. For more details on ProRox wired mat insulation products, contact your ROXUL representative.

Pipe insulation with wired mats has been a time-tested universal solution for many decades now. Due to their flexibility and high temperature resistance, wired mats can be easily cut and mounted onto piping. Wired mats are ideal for application in situations where the use of pipe sections or load bearing wraps (mats) is difficult or impossible. Historically this included large diameter pipes and high temperatures (where the wired mat provided structural integrity to the insulation at high temperatures), but advanced modern ProRox pipe section and ProRox pipe wraps (mats) have provided a suitable alternative to wired mats. Wired mat is still used today in piping with a high number of shaped pieces such as elbows or T-joints.

Wired mats have a relatively low resistance to pressure and from a practical point of view should only be mounted in combination with spacers or support structures. Because of the resulting thermal bridges, better insulation performances are often achieved in thelower and middle temperature range [up to 550 F (300 C)] with pipe sections or load bearing wraps (mats).

25


1. Pipe - 2. Insulation: ProRox Pipe Sections or Pipe Wraps (Mats): ENERWRAP MA 960NA - 3. Cladding

1. Pipe - 2. Insulation: ProRox Wired Mats - 3. Cladding - 4.Spacer ring

Insulation system with a spacer ring

Insulation system without a spacer ring

Comparison of the different insulation systemsThe particular advantage of pipe sections and pipe wraps (mats) lies in the fact that support structures are not required and therefore thermal bridges caused by the insulation are minimized or removed. On the other hand, wired mat systems have their advantages due to their ability to be structurally sound when insulating around irregularly shaped pipe sections.

The advantages of pipe sections and load-bearing pipe wraps (mats) at a glance are:

It is not necessary to install spacers or support structures.

Faster application without the interference of spacers.

Both products offer an even, firm surface for installing the sheet cladding.

The lack of spacers gives rise to lower heat losses.

It yields an even surface temperature across the sheet cladding.

In comparison to wired mats, a more shallow insulation thickness can be applied. Theoperating costs of the installation decrease as a result of lower heat loss.

Generally speaking, a spacer or support structure functions as a thermal bridge, as a result of which theheat loss in the total insulation is increased considerably.

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Required insulation thicknesses If the three insulation systems are compared, taking into consideration similar heat losses, clear advantages are seen with regard to the insulation thicknesses with systems using pipe sections or pipe wraps (mats). These do not use spacers, in contrast to insulation systems made using wired mats. The table below shows the required insulation thicknesses taking into account the following boundary conditions:

Medium temperature: 480 F (250 C) Ambient temperature: 50 F (10 C) Wind speed: 1.1 mph (5 m/s) Cladding: Aluminum Heat loss: 150 BTU/ft.hr (150 W/m) Application of spacers in the case of wired mats

Pipe DiameterMinimum Insulation Thickness

Pipe sections Pipe wraps (mats)Wired mats

NPS(inch)

Nominal diameter DN

Pipe diameter(mm)

ProRox PS 960NA ENERWRAP MA 960NA

inch inch inch

2 50 60 1" n.a. n.a.

3 80 89 1" n.a. n.a.

4 100 108 1.5" n.a. n.a.

6 150 159 2" n.a. n.a.

8 200 219 2.5" n.a. 5"

10 250 273 3" n.a. 6"

12 300 324 4" 4" 7.5"

14 350 356 4.5" 4.5" 8"

Multiple layer insulation n.a. = not applicable

27


Selection of pipe insulation systemsGenerally, the best insulation is achieved using ProRox Pipe Sections. The preformed sections are quick and easy to install. Their excellent fit and high compression resistance means pipe sections can be applied in a single layer without any additional spacers. They also have a lower insulation thickness. Pipe wraps (mats), are usually applied for the insulation of large pipe diameters and can be applied to shaped pieces like elbows and T-joints.

Comparison ProRox pipe sections and pipe wraps (mats) offer theadvantage that spacers are generally not required.

ProRox pipe sections and pipe wraps (mats) are applied more quickly without the inter ference of spacers.

Both products offer an even, firm surface for installing the cladding.

The lack of spacers creates lower heat loss. It yields an even surface temperature

across the cladding. In comparison to wired mats, a more

shallow insulation thickness can be used. With a same insulation thickness, the operational costs of the installation decrease as a result of lower heat losses.

Generally speaking, a spacer or support structure functions as a thermal bridge, as a result of which the heat loss in the total insulation is increased considerably.

The design of an insulation system depends upon many factors such as the dimensions, mechanical loads, safety aspects, economics, etc. Consequently this also requires a considered selection of the insulation material.

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1.2.1 Insulation with pipe sectionsGenerally, the best insulation is achieved using ProRox Pipe Sections. The sections can be used up to temperatures of 1400 F (760 C) when using ProRox PS 980NA Type V insulation. They are supplied ready split and hinged for quick and easy snap-on assembly and are suitable for thermal and acoustic insulation of industrial pipe work. Their excellent fit and high compression resistance means pipe sections can be applied in a single layer without any additional spacers or support structures. Consequently the number of thermal bridges, which have a negative influence on the insulation, is greatly reduced, while a low thickness may be applied compared to wired mats. The result is considerably reduced installation time and costs. The lack of spacers and unforeseen gaps minimizes heat loss and the risk of personnel injuries due to hot spots on the cladding. At temperatures above 550 F (300 C), the provisional application of spacers must be determined in each individual case. ProRox Pipe Sections are available in a wide range of diameters, ranging from NPS 1/2" (23 mm) to 36" (914 mm)

NoteDue to their low thermal conductivity, better thermal insulation values can be achieved with pipe sections than with wired mats. With insulation on straight pipe sections, a combination of both products in the same insulation thickness is therefore not advisable. If this combination is essential, for example, in the case of bends or shaped pieces, it is vital to select the correct insulation thickness. This is the only way to guarantee that no unexpected, potentially hazardous surface temperatures occur.

Insulation thicknesses to guarantee protection against contactThe table below is an initial guide to help select suitable insulation thicknesses for the guards. Itisbased on the following boundary conditions:

Ambient temperature: 75 F (25 C) Wind speed: 1.1 mph (0.5 m/s) Cladding: Aluminum Maximum surface temperature: 140 F (60 C) Insulation: ProRox PS 960NA pipe sections

Pipe Diameter Temperature

NPS(inch)

Nominal diameter

DN

Pipe diameter

(mm)

InstallationBefore starting the insulation works, ensure that all preparatory work on the object has been completed. Refer to Chapter 1.1 for details.

The ProRox PS 900 Series pipe sections are mounted directly onto the pipe to form a close fit. With horizontal pipes, the lengthwise joint of the pipe section should be turned towards the underside at the 6 oclock position. With vertical pipes, the lengthwise joints should be staggered at an angle of 30 to one another. Secure the pipe sections with galvanized binding wire or with steel bands. With an insulation thickness exceeding 5 inches (120 mm) [or temperatures > 550 F (300 C)], install the insulation in at least two layers. If the insulation is assembled in multiple layers, the joints of the individual insulation layers must be staggered.

Support structures and spacersSpacers are not generally essential in insulation systems with pipe sections. With pipes that are exposed to large mechanical loads (e.g. strong vibrations) and/or temperatures above 550 F (300 C), determine whether a spacer ring is required in each individual case.

With pipes that have been installed vertically, with a height in excess of 13 feet (4 m), fit support structures to transfer the dead load of the insulation system onto the pipe. Attach the first support ring to the lowest point of the vertical pipe. The distance between the support rings should not exceed approximately 13 feet (4 m).


1. Pipe - 2. Insulation: ProRox Pipe Sections - 3. Clamp or binding wire - 4. Sheet cladding - 5. Sheet-metal screw or rivet

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1.2.2 Insulation with pipe wraps (mats)Pipe wraps (mats), such as ENERWRAP MA 960NA are the latest development in the insulation business. ENERWRAP MA 960NA is a stone wool insulation wrap available with black mat or reinforced foil facing. The flexible application makes the product easy to cut and install. Pipe wraps (mats) are ideal for installations involving large diameter pipes and a high number of shaped pieces such as elbows or T-joints.

ENERWRAP MA 960NA can be applied up to temperatures of 1200 F (650 C). Due to the high compression resistance, pipe wraps (mats) can be applied without additional spacers in many cases. Consequently, the number of thermal bridges which have a negative influence on the insulation, is greatly reduced.

The result is considerably reduced installation time and costs. The lack of spacers minimizes heat loss and the risk of personal injuries caused by hot spots on the cladding. Pipe wraps (mats) are precisely tailored to the corresponding length of the pipe circumference on site and are fastened with clamps.

Insulation thicknesses to guarantee protection against contactThe table below is an initial guide to help select suitable insulation thicknesses for the guards. It is based on the following boundary conditions:

Ambient Temperature 75 F (25 C) Wind speed: 1.1 mph (0.5 m/s) Cladding: Aluminum Maximum surface temperature: 140 F (60 C) Insulation: ProRox PS 960NA

Pipe Diameter Temperature

NPS (inch)

Nominal diameter

DN

Pipe diameter

(mm)


Cut the wraps (mats) to the required length, based on the external insulation diameter (pipe diameter + two times the insulation thickness). Fasten the wrap (mat) firmly to the pipe with steel bands. Ensure that the wraps (mats) form a tight joint and that no lengthwise joints or circular joints are visible. The joints of the individual wraps (mats) are securely taped with self-adhesive aluminum tape. If the insulation is assembled in multiple layers, the joints of the individual insulation layers must be staggered.

Support structures and spacersSpacers are not generally essential in insulation systems with load bearing wraps (mats). With pipes that are exposed to large mechanical loads (e.g. strong vibrations), determine whether a spacer ring is required in each individual case.

With pipes that have been installed vertically, with a height in excess of 14 feet (4 m), fit support structures to transfer the dead load of the insulation system onto the pipe. Attach the first support ring to the lowest point of the vertical pipe. The distance between the support rings should not exceed approximately 14 feet (4 m).


1. Pipe - 2. Insulation: ENERWRAP MA 960NA - 3. Self-adhesive aluminum tape - 4. Steel bands - 5. Sheet cladding - 6.Sheet-metal screw or rivet

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1.2.3 Insulation with wired matsPipe insulation with wired mats has been a time-tested universal solution for many decades now. Due to their flexibility and high temperature resistance, wired mats can be easily cut and mounted onto the piping. These wired mats are ideal for application on large pipe diameters and shaped pieces as elbows or T-joints.

Wired mats have a relatively low resistance to pressure and from a practical point of view should only be mounted in combination with spacers. Because of theresulting thermal bridges, better insulation performances are often achieved in the lower and middle temperature range [up to 550 F (300 C)] with pipe sections or load bearing wraps (mats) rather than with wiredmats.


Cut the wrap (mat) to a length so that it can be fitted to the pipe with slight pre stressing. Wire the closing joints (lengthwise and circular) of the wraps (mats) together using steel wire or secure with wrap (mat) hooks. Stainless steel pipes and pipes with an operating temperature > 750 F (400 C) can only be insulated with wired mats with stainless steel stitching wire and wire netting to prevent galvanic corrosion cracking.

With an insulation thickness of more than 5 inches (120 mm) [or temperatures > 550 F (300 C)], apply multiple layer insulation. If the insulation is assembled in multiple layers, the lengthwise and crosswise joints of the individual insulation layers must be staggered. If mechanical loads are anticipated, use steel straps to secure the wired mats.

Support structures and spacersAs wired mats do not offer sufficient resistance topressure to bear the weight of the cladding, spacer or support structures should be applied. More information can be found in 1.2.4.

With pipes that have been installed vertically, witha height in excess of 14 feet (4 m), fit support structures to transfer the dead load of the insulation system onto the pipe. Attach the first support ring to the lowest point of the vertical pipe. The distance between the support rings should not exceed approximately 14 feet (4 m).

1. Pipe - 2. Insulation: ProRox Wired Mats - 3. Stitching of the joint edge with binding wire - 4. Sheet cladding - 5. Sheet-metal screw or riveted bolt - 6. Spacer ring

1. Pipe - 2. Insulation: ProRox Wired Mat- 3. Joint edge closed with mat hooks - 4. Sheet-metal cladding - 5.Sheet-metal screw or riveted bolt - 6. Spacer ring

33

1.2.4 Insulation support A. SpacersThe purpose of spacers is to keep the cladding at a predetermined distance from the pipe. Spacers are essential when the insulation (e.g. wired mats) cannot bear the mechanical load of the cladding. The use of spacers is generally not necessary ifpipe sections or pipe wraps (mats) are used.Consideration should be given to support structure or spacers on pipes where mechanical loading (e.g. strong vibrations) of the insulation is expected and/or the temperature is higher than 550 F (300 C).

Spacer rings usually consist of metal rings on which the sheet cladding rests, and metal or ceramic bars used as spacers, which rest on the pipe. Elastic spacers such as Omega clamps are frequently used to reduce the transference of vibrations. With steel spacers, apply at least three bars, whereby the maximum distance measured as circumference of the external ring must be a total of maximum 16 inch (400 mm). With ceramic spacers, apply at least four bars at a maximum permissible distance of 16 inch (400 mm).

Dimension spacers of support constructionThe number of spacers depends on the insulation, temperature and the mechanical load. Use the following intermediate distances as a guide.

Insulation system

Horizontal piping

Verticalpiping

550 F > 550 F 550 F > 550 F

Pipe sections none 10 to 13 ft none 16 to 20 ft

Load bearing wraps (mats) none 10 to 13 ft none 16 to 20 ft

Wired mats 3.3 ft 3.3 ft 3.3 ft 16 to 20 ft

The spacers on pipes are located under the circular joint of the cladding. On shaped sections such as pipe elbows, spacers are fitted at the start and at the end. If the external distance between the two spacers exceeds 27 inch (700 mm), place additional spacers between the two.


1. Pipe - 2. ProRox insulation - 3. Spacer - 4. Thermal dividing layer - 5. Support ring

max

. 16"

(400

mm)

1. Pipe - 2. ProRox insulation - 3. Spacer - 4. Thermal dividing layer - 5. Cladding

max

. 27"

(700

mm)

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B. Support constructionThe purpose of support structures is to transfer the mechanical load of the insulation system and the forces affecting the insulation system onto the object. Support structures are essential in the case of vertical piping. In addition to the static and dynamic forces, changes in piping length and support structures due to temperature must also be taken into account when dimensioning. Support structures are fastened to mounting supports, which are welded to the pipe beforehand, or are mounted directly onto the pipe via a clamping action with so-called double clamping rings. With temperatures above 650 F (350 C), the support structures must be made of high-temperature steels. The table below is an initial dimensioning guide, and shows the weight of the insulation system against the nominal width of the pipe and the insulation thickness. The table accounts for an insulation with an apparent density of 6 lb/ft3 (100 kg/m), including the spacer and a 0.20 inch (1.0 mm) strong galvanized sheet.

Weight of the insulation (lb/ft pipe)

1. Support ring - 2. Bar - 3. Rivet or screw connection - 4. Thermal decoupling - 5. Clamping screw - 6. Screw nut - 7. Internal clamping ring

Pipe DiameterUnits of weight ofinsulation system

Insulation Thickness (inch)

NPS(inch)

Nominal diameter

DN

Pipe diameter

(mm)1.00 1.50 2.00 2.50 3.00 4.00 5.00 6.00

0.5 15 21 lb / ft 0.3 0.5 0.8 1.1 1.5 2.5 3.7 5.2

1.0 25 34 lb / ft 0.5 0.7 1.0 1.4 1.8 2.8 4.1 5.7

2.0 50 60 lb / ft 0.8 1.1 1.5 1.9 2.4 3.6 5.0 6.7

2.5 65 76 lb / ft 1.0 1.3 1.7 2.2 2.7 4.0 5.5 7.2

3.0 80 89 lb / ft 1.2 1.5 2.0 2.5 3.0 4.3 5.9 7.7

4.0 100 114 lb / ft 1.5 2.0 2.5 3.0 3.6 5.1 6.8 8.7

8.0 200 219 lb / ft 2.9 3.6 4.4 5.2 6.1 8.1 10.3 12.8

12.0 300 324 lb / ft 4.4 5.3 6.3 7.4 8.5 11.0 13.8 16.8

20.0 500 508 lb / ft 7.2 8.6 10.2 11.8 13.5 17.0 20.8 24.8

28.0 700 711 lb / ft 10.0 12.0 14.0 16.2 18.4 22.9 27.8 32.9

planar surface lb / ft2 1.3 1.6 1.8 2.1 2.3 2.8 3.3 3.8

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1.2.5 CladdingSuitable cladding should be applied to protect the insulation from weather influences, mechanical loads and (potentially corrosive) pollution. Selecting the appropriate cladding depends on various factors, such as working loads, foot traffic, wind and snow accumulations, ambient temperatures and conditions.

Note An insulation system resistant to foot traffic must not become permanently damaged if a person weighing 220 lbs (100 kg), (weight including any tools being carried) walks across it. It is not designed to bear additional loads, such as the placing of heavy equipment. For the purpose of the safety regulations, a durable insulation is not considered to be a walkable surface.

When selecting the appropriate cladding, take the following points into account:

As a general rule, galvanized steel is used in buildings due to its mechanical strength, fire resistance and low surface temperature (in comparison to an aluminum cladding).

Aluminum is used outdoors, because it is easy to fit and more cost-effective than stainless steel and does not tend to corrode under common weather conditions.

In corrosive environments, aluminized steel, stainless steel or glass reinforced polyester is used as cladding. Stainless steel is recommended for use in environments with a fire risk.

The surface temperature of the cladding is influenced by the material type. The following applies as a general rule: the shinier the surface, the higher the surface temperature.

To exclude the risk of galvanic corrosion, only use combinations of metals that do not tend to corrode due to their electrochemical potentials (also see page 21 in Chapter 1.1).

For acoustic insulation, a noise absorbent material (bitumen, mylar foil) is mounted on the insulation or inside the cladding. To reduce the risk of fire, limit the surface temperatures of the cladding to the maximum operating temperature of the noise absorbent material.


Max. surface temperature

Cladding material Areas at risk of fire

Corrosive environment

< 120 F (50 C)

< 140 F (60 C)

> 140 F (60 C)

Aluminum sheet - -

Aluminum/zinc coated steel sheet - -

Galvanized steel sheet -

Austenitic stainless steel sheet

Aluminized steel sheet

Plastic-coated steel or aluminum - -

Glass fiber-reinforced polyester (e.g. ProRox Rocktight) - < 190 F (90 C)

Coatings/mastics - - 175 F (80 C)

Foils - -

The thickness of the metal sheet depends on the pipe dameter and the type of the metal. With special acoustic requirements, a larger thickness [> 0.04" (1 mm)] is generally used.

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The recommended sheet thickness deviates to a certain level per standard/country. The thickness recommended by CINI is shown in the table above (values converted to inches). See page 148 in Chapter 3.2.2 for the thickness according to DIN 4140 and BS 5970.

To reduce the risk of galvanic corrosion, it is important to use the correct screws, straps etc. See the table on page 21 for more information.

The basic guidelines are: Fasten sheet cladding on lengthwise joints with

at least six sheet metal screws or blind rivets every meter.

Place the screws or blind rivets equidistant. Ifscrews or rivets are fitted in two rows, do not stagger the screws or rivets.

The cladding can also be held in place with corrosion-resistant straps instead of screws orrivets.

Do not use aluminum screws.

Influence of the cladding on the surface temperatureIn addition to the insulation thickness, the thermal conductivity of the insulation and the ambient conditions (for example temperature and wind), the surface temperature of insulation is also influenced by the emission ratio (emissivity) of the cladding.

The following applies as a general rule for thermal insulation: the shinier a surface is (lower emissivity), the higher the surface temperature. The following example shows the various surface temperatures that depend on the cladding:

Diameter: 4 1/2" (114 mm) Temperature of the medium: 930 F (500 C) Place of installation: Interior [Wind speed 1.1

mph (0.5 m/s)] Insulation: ENERWRAP MA 960NA

pipe wrap (mat), thickness 4" (100 mm) Various cladding materials

- Aluminum sheet - Galvanized steel sheet, bright - Stainless steel - Paint-coated plastic cladding

Recommended sheet thickness and overlaps regarding cladding made from flat sheets (CINI)

External diameter of the insulation (in)

Minimum thickness (inches) of metal cladding sheet (recomended by CINI)

Aluminum(CINI 3.1.01)

Aluminized steelsheet

(CINI 3.1.02)

Alu-Zinc coated steel sheet

(CINI 3.1.03)

Zinc coated steelsheet

(CINI 3.1.04)

Austenitic stainless steel sheet

(CINI 3.1.05)

< 5.5" 0.024 0.022 0.020 0.020 0.020

5" to 12" 0.031 0.031 0.031 0.031 0.031

> 12" 0.039 0.031 0.031 0.031 0.031

Surf

ace

(cla

ddin

g) t

empe

ratu

re

F

Aluminumcladding

100

105

110

115

120

125

130

Galvanizedsteel

Stainlesssteel

Paint-coatedPlastic

cladding

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1.2 Insulation of piping 1.2.5 Cladding

Cladding in corrosive environmentsTo guarantee the functionality of industrial/mechanical insulation (sometimes referred to as technical insulation), it is important to protect it against atmospheric influences and prevent the ingress of moisture into the insulation. Moisture in the insulation system increases thermal conductivity, thereby reducing the effectiveness of the thermal protection. It also poses a high risk of corrosion to the component. In certain applications, the cladding system is also expected to offer chemical resistance, as well as being resistant to cleaning methods such as steam blasting. Alongside the insulation and construction, selecting a suitable cladding system is very important as it forms the basis for a long service life, low maintenance costs and low heat loss of a industrial/mechanical insulation. ROXUL offers ProRox Rocktight, an innovative fiberglass polyester cladding system.

ProRox Rocktight a durable protection for insulationProRox Rocktight is a fiberglass reinforced polyester wrap, which hardens when exposed to ultraviolet (UV) light. The material contains resins, glass fibers and a special filling agent and is (unprocessed) protected against UV rays by foils on both sides.

ProRox Rocktight is soft and flexible when unprocessed. Itcan be cut or trimmed in any shape and easily mounted onto the insulation in this state.

Thepolyester then hardens when exposed to ultraviolet (UV) light. Once hardened, ProRox Rocktight is watertight and forms a mechanical protection for the insulation.

The advantages: Long service life: ProRox Rocktight creates a sealed, watertight cladding for ROXUL insulation systems. This minimizes damage caused by atmospheric influences or general wear and tear. ProRox Rocktight is resistant to many chemical substances and forms a mechanical protection for the insulation. Easy to clean: Insulation systems cased in ProRox Rocktight can be cleaned with steam-jet air ejectors, without the risk of water penetrating the insulation and causing damage. Low start-up costs: The cutting and processing take place directly on site. This avoids costs associated with prefabrication of steel cladding. Flexible applications: ProRox Rocktight can be used for cold and thermal insulation of underground and aboveground pipes, for example in offshore plants. Its high flexibility enables application on complex, shaped objects.

ProRox Rocktight is characterized by easy processing. It can be cut easily using a knife directly on site and, as an unhardened ProRox Rocktight wrap (mat) is highly flexible, it can be simply shaped to cover complex geometric shapes such as pipe elbows, T-joints or pipe fittings. ProRox Rocktight has a protective foil on both sides. It is supplied in rolls in cardboard packaging. The roll is also wrapped in black foil that is resistant to UV light. The underside (the side facing the object) is covered with a dark foil and has a rough, self-adhesive surface. The flat surface of the outside is covered with a white foil. After each use, place the roll in the sealed cardboard packaging to minimize the risk of hardening caused by daylight or UV light.

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Pipe hangers in direct contact with the piping

ProRox Rocktight requires a dry, clean (ventilated) work environment. For outdoor applications, tents should be erected if necessary, to protect the unhardened ProRox Rocktight wrap (mat) from UV light.

Note High temperatures: ProRox Rocktight can

be used in temperatures of up to 190 F (90 C).

Chemical resistance: ProRox Rocktight is resistant to numerous chemicals.

Expansion joints: fit expansion joints to accommodate expansion of the ProRox Rocktight material and the steel pipe.

1.2.6 Pipe hangers and pipe supports There is a wide range of solutions for pipe hangers and pipe supports. The following illustrations show the possibilities described below for insulation systems:

Pipe hangers in direct contact with the piping Pipe supports in direct contact with the piping Pipe supports not in direct contact with the

piping (commonly used with cold insulation systems)

A basic rule applying to all pipe attachments is that the insulation system (e.g. the insulation and cladding) must not be damaged if the piping expands. Damage to the cladding of outdoor installations, in particular, can allow the ingress ofmoisture in the material. The result may be permanent damage of the insulation system andas a consequence high heat losses, dangerously high surface temperatures and corrosion etc.

1. Pipe - 2. Insulation: ProRox PS 960NA pipe sections- 3.Sheet cladding - 4. Load-bearing insulation - 5.Seal - 6.Stirrup - 7. Pipe saddle

Pipe support not in direct contact with the piping

1. Pipe - 2. Insulation: ProRox Pipe Sections - 3.Collar - 4. Sheet cladding - 5. Pipe hanger

1. Pipe - 2. Insulation: ProRox PS 960NA pipe section - 3.Sheet cladding - 4. Pipe clamp - 5. Pipe saddle

Pipe support in direct contact with the piping

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1.2.7 Insulation of valves and flanges Heat loss incurred through non insulated fixtures such as valves and flanges are substantial, even at low temperatures. An uninsulated valve located outside loses as much heat at 250 F (120 C) as 100 ft (30.5 m) of uninsulated piping. The temperature of the medium can also decrease to such an extent at non-insulated fittings or flanges, that process critical temperatures are reached, at which point for example, the medium will start to crystallize. Valves and flanges should therefore be insulated as much as possible. To avoid damage during inspection or repairs, the insulation for valves and flanges is designed with removable coverings or hoods, to allow rapid disassembly. Removable coverings or hoods are usually insulated from the inside with wired mats or flexible ProRox insulation (FSL Series). The coverings are fastened to the object with lever fastenings, which are fixed directly onto the covering or on to straps. Take the following conditions into account when designing insulated coverings for fittings and flanges:

The overlap distance of the insulated covering over the insulated pipe should be at least 2"

(50 mm). The pipe insulation should end at the flanges,

leaving a gap equal to the bolt length +1.2" (30 mm) and should be closed off with a lock washer so the flange can be loosened without damaging the insulation.

With valves, an extended spindle should preferably be fitted horizontally or below the pipe to prevent leakage along the spindle shaft.

The cladding must be fitted to prevent the ingress of moisture in the insulation. On inclined or vertical piping, for example, mount rain deflectors above the removable coverings. If the ingress of moisture into the insulation is unavoidable, make 0.4" (10 mm). diameter drain holes in the removable covering.


1. Pipe - 2. ProRox insulation- 3. Cladding- 4. Sheet-metal screw or Rivet - 5.Swage- 6.Drainage opening - 7. Strap - B 2" (50 mm) - A= bolt length +1.2" (30 mm)

1. Pipe - 2. ProRox insulation - 3. Cladding- 4. Sheet-metal screw or rivet - 5. Rain deflector - 6. Lock washer - 7. Straps - 8. Rain deflector - B 2" (50 mm) - A = bolt length + 1.2" (30 mm)

2"

(50

mm

)

5

0.8"(20 mm)

A number of possible design options for insulation systems for pipe fittings and flanges follow:

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LeakagesWith pipes where a leaking fluid content could damage the insulation or the coating system in the removable covering, mount flange straps with a leak detection fitting around the flange. Flange bands can also prevent flammable products from penetrating into the insulation material and can help prevent the outbreak of fire.

1. Pipe - 2. ProRox insulation - 3.Cladding - 4. Sheet-metal screw or rivet - 5. Swage- 6.Drainage opening - 7. Straps B 2" (50 mm) - A = Bolt length + 1.2" (30 mm)

1. Pipe - 2. Insulation: ProRox Pipe Sections - 3. Cladding - 4. Sheet-metal screw or rivet - 5. Removable coverings (insulated from the inside) - 6. Swage

2"

(50

mm

)

0.8"(20 mm)

1. Pipe - 2. ProRox insulation - 3.Sheet - 4. Sheet-metal screw or rivet - 5. Rain deflector - 6. Lock washer - 7. Straps - 8. Lock washer - B 2" (50 mm) - A = Screw length +1.2" (30 mm)

1. Pipe - 2. ProRox insulation - 3. Cladding- 4. Sheet-metal screw or rivet - 5. Swage - 6.Flange band - 7. Leak detection fitting - 8. Clamps

1. Pipe - 2. ProRox insulation - 3. Cladding- 4. Sheet-metal screw or rivet - 5. Swage - 6.Drainage opening - 7. Straps B 2" (50 mm)

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1.2 Insulation of piping 1.2.7 Insulation of valves and flanges

1.2.8 Insulation of pipe elbows and tpieces

The cladding of elbows and T-pieces is susceptible to damage, due to expanding or vibrating pipes. There is a particular risk of moisture penetrating damaged swage connections in the cladding, if the object is located outdoors.

For the insulation of shaped pieces, we recommend using the same insulation in the same thickness as used for the pipe.

Insulation of pipe elbows with RoXUL pipe sectionsFor the insulation of pipe elbows with pipe sections (e.g. ProRox PS 960NA), the pipe sections are cut into segments and tightly fitted onto the pipe elbow with the lengthwise joints facing downwards. The angular division of the segments should correspond to the radius of the pipe elbow. The pipe section segments are fastened to the

pipe elbow with clamps or binding wire. Joints between the individual segments are plugged tightly with loose ROXUL insulation.

Insulation of pipe elbows with wired mats or ProRox pipe wraps (mats)If the piping is insulated with wired mats or pipe wraps (mats), shaped pieces such as pipe elbows or T-pieces are generally insulated with the same wraps (mats). In this case, the wraps (mats) are cut into so-called fish-shaped elbow segments. These are mounted onto the pipe elbow to seal the elbow. With wired wraps (mats), all the joints (both circular and lengthwise joints) are sewn together with binding wire or wrap (mat) hooks. Spacers are required at least at the start and end of the elbow (for more details, please see page 34).

Pipe wraps (mats) are fixed to the pipe elbow with metal or plastic straps. Any gaps between the individual segments should be plugged with insulation. Secure the joint edges with self-adhesive aluminum tape.

1. Pipe - 2. ProRox insulation - 3. Cladding - 4. Sheet-metal screw or rivet - 5. Collar - 6. Collar - 7. Clamps - 8.Rain deflector - 9. Leak detection fitting - B 2" (50 mm) - A = bolt length + 1.2" (30 mm)

1. Pipe - 2. Insulation: ProRox Pipe Sections - 3.Cladding - A and B = Segmented pipe sections

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1.2.9 ReducersPipes that branch out with many outlets reduce the pipe diameter. Examples of how to install reducers follow:

The diagrams below show how the sheet is mounted onto shaped pieces.

1. Pipe - 2. ProRox insulation - 3. Cladding - A to C: Elbow segments of wraps (mats)

1. Pipe - 2. ProRox insulation - 3. Cladding

1. Pipe - 2. ProRox insulation - 3. Cladding - 4. Drainage opening - 5.Edging with mastic compound

0.6" (

15 m

m)

0.4

" (1

0 m

m)

1. Pipe - 2. ProRox insulation - 3. Cladding - 4. Sheet-metal screw or rivet- 5.Swage - 6. Reducer

1. Pipe - 2. ProRox insulation - 3. Cladding - 4. Sheet-metal screw or rivet- 5.Swage - 6. Reducer

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1.2.10 expansion jointsIn thermal insulation systems, large differences between the piping and the cladding temperature can occur. The materials used for the pipe, insulation, insulation support and cladding also have different thermal expansion coefficients. Thisleads to different thermal elongations of the various components in the insulation system, which must be allowed for using constructive measures. The elongation l can be determined as follows:

l = l t a

In this formula, l corresponds to the length of the pipe, t corresponds to the difference in temperature between the cold and warm pipe (or cladding) and a corresponds to the linear thermal expansion coefficient (see tables in Chapter 3).

If bellow expansion joints for thermal length compensation have been built into the pipe, the insulation system will also bellow along with the pipe movements, potentially compromising the insulation. The expansion bellows are covered with a sheet that is then insulated (see diagrams on the right). With temperatures above 550 F (300 C), do not use galvanized sheets due to the risk of galvanic corrosion (cracking).

To compensate for thermal expansion of the cladding, install the expansion joints shown below.


Example for the thermal elongation of steel

l (inch per foot) t (F) t (C)

0.004 50 28

0.008 100 56

0.012 150 83

Industrial Insulation Manual

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